Sr Process Development Engineer

FormFactor • Livermore, CA

6d • Onsite

About The Position

FormFactor is seeking a Sr Process Development Engineer to support the development, characterization, and commercialization of new products, materials, and manufacturing technologies. This role focuses on creating, testing, optimizing, and scaling innovative manufacturing processes from research and development through pilot production and full manufacturing implementation. Working under general direction, the Sr Process Development Engineer applies engineering principles, statistical analysis, and experimental methodologies to develop robust manufacturing processes that improve product performance, quality, yield, and manufacturability. The successful candidate will collaborate closely with R&D, Manufacturing, Product Engineering, Quality, Equipment Engineering, and external suppliers to evaluate new technologies, lead process development activities, and support new product introductions. This position offers the opportunity to wear many hats in a fast-paced, high-technology environment while driving innovation and enabling next-generation products.

Requirements

• Bachelor’s degree and a minimum of 2 years of related experience; or an advanced degree without experience; or equivalent work experience
• Engineering experience in process development, manufacturing engineering, product development, or a related technical field.
• Experience utilizing statistical analysis techniques, DOE methodologies, SPC, and process capability tools.
• Strong analytical and problem-solving skills with demonstrated experience troubleshooting complex manufacturing or development challenges.
• Ability to work effectively in cross-functional environments and manage multiple priorities.
• Cross-disciplinary education or experience spanning materials, manufacturing processes, equipment, and product development.
• Hands-on experience developing and scaling manufacturing processes from R&D through production.
• Demonstrated track record of successfully transferring processes from R&D into manufacturing.
• Experience supporting semiconductor, electronics, advanced materials, MEMS, precision manufacturing, or related industries.
• Experience developing adhesive, dispensing, assembly, packaging, or automation processes.
• Knowledge of process qualification methodologies, risk assessments, PFMEA, and change control practices.
• Proficiency with JMP, Minitab, Python, Excel, or similar engineering data analysis tools.

Nice To Haves

• Bachelor's degree in Mechanical Engineering, Materials Science, Chemical Engineering, Manufacturing Engineering, or a related engineering discipline.

Responsibilities

• Develop, evaluate, and implement new manufacturing processes, materials, and technologies to support new product initiatives.
• Conduct technology assessments and feasibility studies for next-generation products and manufacturing methods.
• Design and execute process development plans to transition concepts from laboratory and pilot phases into production-ready solutions.
• Perform hands-on engineering work to establish, optimize, and sustain new and existing manufacturing processes.
• Design, execute, and analyze experiments utilizing Design of Experiments (DOE) methodologies.
• Characterize products, materials, equipment, and process outputs to verify performance against customer and engineering requirements.
• Utilize statistical analysis techniques, process capability studies, and Statistical Process Control (SPC) methods to evaluate process performance.
• Analyze process data to identify trends, root causes, and opportunities for improvement.
• Support New Product Introduction (NPI) activities from concept development through manufacturing release.
• Collaborate with cross-functional teams to develop scalable manufacturing solutions that meet cost, quality, reliability, and schedule objectives.
• Assist in product and process qualification activities, including validation testing and process capability assessments.
• Support pilot builds and manufacturing readiness activities for new products.
• Lead and support the transfer of new processes and technologies from R&D into manufacturing environments.
• Create and maintain work instructions, process flows, specifications, training materials, and supporting documentation.
• Provide training and cross-functional knowledge transfer to manufacturing teams.
• Troubleshoot process-related issues and implement corrective and preventive actions to improve process stability and performance.
• Develop and integrate new manufacturing process modules and equipment into existing production platforms.
• Support development of specialized assembly processes, including adhesive and epoxy dispensing applications.
• Work closely with equipment vendors, suppliers, and fabricators to source, evaluate, and improve materials and tooling solutions.
• Participate in equipment selections, qualifications, and acceptance activities.
• Identify and implement process improvements that enhance yield, quality, throughput, reliability, and cost performance.
• Lead or support process development projects of moderate scope and complexity.
• Prepare technical reports, presentations, risk assessments, and engineering recommendations.
• Collaborate with Manufacturing, Quality, Supply Chain, Product Engineering, and R&D teams to drive successful project outcomes.

Benefits

• medical, dental, vision, life insurance, disability coverage, a 401(k) with company match, employee stock purchase plan (ESPP), and paid time off.
• quarterly profit-sharing bonuses
• flexible spending or savings accounts.

What This Job Offers

• Job Type: Full-time
• Career Level: Senior